ABBAdvant Controller 31 40 & 50 Series

. Presentation

The AC 31 brings accessibility to beginners and experienced automation users alike, for any

application with 14 to 1000 inputs / outputs and more, using the same set of basic

components.

From a compact machine fitted with a few automated functions to large installations spread

over hundreds of meter, and even kilometers, the AC 31 can fit your requirements.

It is therefore possible to realize distributed applications throughout a site, a workshop, or a

machine where each component (input / output unit, central unit) is close to the sensors /

actuators. The whole setup is connected by a single twisted pair over which all information

from the sensors is sent after processing by the central unit to the actuators, as well as

distributed intelligent units. The following communication interfaces are available, to extend the

AC 31’s possibilities and integration with the company's other automation systems:

MODBUS
, ASCII, ARCNET
, RCOM, AF100. The developments in this field are continual.

Many users on all the continents have realized numerous applications such as:

Machine control

Manufacture of floor boards

Assembly of electrical contactors

Manufacture of ceramic products

Metallic pipe welding, etc.

Controlling-commanding installations

Wharf cranes

Water treatment

Ski lifts

Wind power machines, etc.

Systems management

Climatic management

Building power management

Tunnel ventilation

Alarms in hospital environments

Greenhouse lighting / humidity, etc.

 General setup rules

An ABB AC 31 system always includes an AC 31 central unit. There are three types of central

units:

- The 40 series central unit, with a local inputs / outputs extensions interface

- The 50 series central unit, with a local inputs / outputs extensions interface

and a CS 31 bus interface

- The 90 series central unit, with a CS 31 bus interface

Each central unit incorporates a specific number of binary inputs / outputs and occasionally

analog. It is possible, depending on the central unit, to increase the number of inputs / outputs,

to add input / output extensions connected directly to the central units or remote input / output

units via the CS 31 twisted pair.

2.1. Central units with extensions

The 40 and 50 series. It’s possible to increase the number of inputs / outputs of the basic

central unit by adding up to 6 local extension units of either type, binary or analog (Figure 1-1).

2.2. Central units with CS 31 bus

The 50 and 90 series. It’s possible to increase the number of inputs / outputs of the basic

central unit by adding remote units. The central unit controlling the system is called the

MASTER central unit. The maximum bus length is 500 m without an amplifier and 2000 m with

3 amplifiers (1 NCB or NCBR unit enables bus amplification for 500 m).

The master central unit can manage up to 31 connection points called SLAVES, such as:

- A remote unit with extension possibilities: a maximum of 6 extension units comprising of a

maximum of 8 analog input channels and 8 analog output channels

- A simple remote unit (without extension) with analog or binary inputs / outputs

- A remote TCAD display

- An ABB NCSA-01 variable speed drive interface

- A high speed counter unit

- A central unit (50 series with extension possibilities, 90 series and the previous 30 series)

- Or any other device which disposes of a CS 31 communication (see Figure 1-2).

Comment:

A slave fitted solely with binary channels occupies 1 connection point.

A slave fitted with binary and analog channels occupies 2 connection points of the available

31.

The maximum number of remote ANALOG units depends on the MASTER central unit:

- 50 series: - a maximum of 31 remote analog input units

- a maximum of 31 remote analog output units

- a maximum of 15 extensible remote units (ICMK14F1) with analog input / output

extensions + 1 remote analog input / output unit (15 x 2 + 1 = 31)

- or a mixed binary / analog configuration within the previous limits

- 90 series: - a maximum of 12 remote analog input units

- a maximum of 12 remote analog output units

- or a maximum of 12 slaves with analog extensions

Other Option: You have a possibility to use and configure the CS31 bus in Modbus® slave or

master see chapter 7 communication Modbus®

.

2.3. Cabling techniques

Connecting a central unit without a remote unit is simple and corresponds to normal electrical

standards. The electrical connections of a AC 31 system which consists of remote units,

notably where there are numerous electrical cubicles, should adhere to the obligatory rules.

These rules are presented in chapter 4.

3. Operation of the 40 and 50 series central units

3.1. Functional diagram

The 40 and 50 series central units memory is composed of two distinct areas:

- A SRAM memory where the user program and data is loaded.

- A Flash EPROM memory which contains:

- a backup of the user program with the program constants,

- the configuration data,

- and the system program protected against access from the user program.

An incorporated battery, which is available only in the 50 series, also enables the backup of

internal variables.

The user program is a set of universal functions conceived by the constructor to cover all

applications and ensure all the basic PLC functions. It is developed with the AC31GRAF

software. After being translated into instructions understable by the central unit it is loaded in

RUN or STOP mode into the SRAM and then saved from the SRAM to the Flash EPROM.

Thereby, at each program launch the user program, saved in the Flash EPROM, is copied to

the SRAM for processing by the microprocessor (Figure 1-3).

The structure of the system program memory, the user program, the inputs / outputs and

internal variables are described in the annex (mapping).

The central unit microprocessor ensures the cyclic execution of the system as shown in

Figure 1-4.

The internal processing:

- PLC monitoring and control

- and processing requests from the terminal operator,

is executed in parallel with the previously described cycle.

The main program is processed sequentially. It may call up to a maximum of 12 sub-programs.

Each sub-program may be called numerous times in the main program.

Three types of interruptions may be executed parallel to the main program:

- A cyclic interruption

- A warning interruption triggered by an event on the I 62.03 input

- A warning interruption triggered by an event on the I 62.02 input

The interruptions have priority over the main program execution. If all three interruptions are

triggered simultaneously then the interruption triggered by I 62.03 has priority over the I 62.02

input interruption which in turn has priority over the cyclic interruption. Once an interruption has

been launched it cannot be interrupted by another (Figure 1-5).

The execution duration of a cycle (bus cycle + program cycle) is controlled by the central unit.

Any excess of the cycle time defined by the user in AC31GRAF is signaled by the ERR Led, at

the front of the central unit, as of the first program cycle.

3.3. Bus transmission

The master central unit manages the transmission of messages to the various slaves over a

RS485 serial liaison.

The messages are transmitted under the following format:

- Request from the master central unit:

address data CRC8

- Request from the remote units:

start data CRC8

The messages always end with an end of frame control: checksum CRC8.

The length of the exchanged frames depends on the type of unit. Frames exchanged with an

analog unit are the longest

The central unit interrogates the remote units in order to establish an initial image of the

system configuration during initialization.

The remote units are then interrogated with each bus cycle. This enables the recognition of

newly added or removed remote units and the updating of the diagnosis information.

If the central unit receives a message indicating a CRC8 error it will not be signaled

immediately and the frame will not be taken into account. After nine consecutive transmission

errors a “bus error” is signaled by the central unit. The bus error is also signaled to the remote

units after a 250 ms time-out.

3.4. Refresh times / reply times

Bus refresh times and central unit reply times depend on the system configuration, the number

and the type of remote units on the CS 31 bus. The bus refresh and the user programs are

executed in series.

3.4.1. Bus refresh times

The bus refresh time corresponds to the transmission time over the bus. The calculation

corresponds to the addition of all the communication times of the remote units on the bus and

the base time of the master central unit which is 2 ms.

3.4.2. Central unit reply times

The central unit reply time corresponds to the time taken to activate an output after the

activation of an input.

The maximum reply time is obtained by adding the filtering time of the input, the bus refresh

time, the delay time for the output and twice the cycle time.

The filtering time for an input on the 40 and 50 series is 5 ms.

The delay time for a transistor output is considered as null in milliseconds and the delay time

for a relay output is 6 ms.

Comment:

The inputs / outputs of central units and their extensions can be accessed, for rapid

processing, independently of the cycle time with the user program functions DI and DO (see

chapter 6).

The cycle time calculation is given in chapter 5 at the cycle time configuration level as well as

the communication times of each unit for the bus transmission times calculation.

3.5. Power on / program launch

The central unit executes a complete series of auto tests at each startup. The program can

only be launched if no errors have been detected.

The auto tests verify the following:

- the program syntax,

- the data transmission,

- the status of the extensions,

- the status of the remote units if there is a master central unit,

- the startup conditions (reset or not of internal memories).

The central unit initialization depends on the startup type:

3.6. Power cuts or drops

The 40/50 series central unit disposes of a time delay in order to save the necessary

information for the next startup should there be a power drop or cut.

Saving program internal data is only possible on the 40/50 series central unit which possesses

an battery. Prior configuration of the central unit is required to save all or part of the data (see

chapter 5). If the configuration is absent then all functions and internal data will be reset to 0.

The intermediate calculations of the functions used in the user program, necessary for the

following cycles, are placed in variables called historic variables. It is also possible to save

historic variables

Presentation / operation

Central units

40 Series

07 CR 41 24VDC Extensible stand-alone central unit,

with 8 isolated inputs 24 V d.c. and 6 incorporated relay outputs

250 V a.c. / 2 A

RS232 interface for programming or ASCII or MODBUS

communication

24 V d.c. power supply.

1SBP260020R1001

07 CR 41 120/230VAC Extensible stand-alone central unit,

with 8 isolated inputs 24 V d.c. and 6 incorporated relay outputs

250 V a.c. / 2 A

RS232 interface for programming or ASCII or MODBUS

communication

24 V d. c. power supply output to power inputs

120 / 230 V a.c. power supply

1SBP260021R1001

07 CT 41 24VDC Extensible stand-alone central unit,

with 8 isolated inputs 24 V d.c. and 6 incorporated transistor

outputs 24 V d.c. / 0.5 A

RS232 interface for programming or ASCII or MODBUS

communication

24 V d.c. power supply

1SBP260022R1001

50 Series

07 KR 51 24VDC Extensible central unit with CS31 bus

with 8 isolated inputs 24 V d.c. and 6 incorporated relay outputs

250 V a.c. / 2 A

RS232 or RS485 interface

for programming or ASCII or MODBUS
communication

24 V d.c. power supply

1SBP260010R1001

07 KR 51 120/230VAC Extensible central unit with CS31 bus

with 8 isolated inputs 24 V d.c. and 6 incorporated relay outputs

250 V a.c. / 2 A

RS232 or RS485 interface

for programming or ASCII or MODBUS
communication

24 V d.c. power supply output to power inputs

120 / 230 V a.c. power supply.

1SBP260011R1001

07 KT 51 24VDC Extensible central unit with CS31 bus

with 8 isolated inputs 24 V d.c. and 6 incorporated transistor

outputs 24 V d.c. / 0.5 A

RS232 or RS485 interface

for programming or ASCII or MODBUS
communication

24 V d.c. power supply

1SBP260012R1001

Programming software

ABB AC31GRAF Programming software for central units,

under Windows
3.x, NT and 95/98. English version

1SBS260250R1001

ABB AC31GRAF Programming software for central units,

under Windows
3.x, NT and 95/98. French version

1SBS260251R1001

ABB AC31GRAF Programming software for central units,

under Windows
3.x, NT and 95/98. Italian version

1SBS260252R100

Presentation / operation

Products Description References

Central units

90 Series

07 KR 91 230VAC Extensible central unit with CS31 bus, memory

20 isolated inputs 24 V d.c. and 12 relay outputs 250 V a.c. / 2 A

120/230 V a.c. power supply.

GJR5250000R0252

07 KR 91 24VDC Extensible central unit with CS31 bus

20 isolated inputs 24 V d.c. and 12 relay outputs 250 V a.c. / 2 A

24 V d. c. power supply

GJR5250000R0202

07 KT 92 24VDC Extensible central unit with CS31 bus

12 isolated inputs 24 V d.c. and 8 transistor outputs 24 V d.c. / 0.5 A

with 4 analog inputs and 2 analog outputs

interface for programming or ASCII or MODBUS
communication

24 V d.c. power supply

GJR5250500R0202

07 KT 92 24VDC Extensible central unit with CS31 bus

12 isolated inputs 24 V d.c. and 8 transistor outputs 24 V d.c. / 0.5 A

with 4 analog inputs and 2 analog outputs

interface for programming or ASCII or MODBUS
and ARCNET

communication

24 V d.c. power supply

GJR5250500R0262

07 KT 93-S 24VDC Extensible central unit with CS31 bus

24 isolated inputs 24 V d.c. and 16 transistor outputs 24 V d.c. / 0.5 A

with security automation

24 V d.c. power supply

GJR5251300R2171

07 KT 93 24VDC Extensible central unit with CS31 bus

24 isolated inputs 24 V d.c. and 16 transistor outputs 24 V d.c. / 0.5 A

interface for programming or ASCII or MODBUS
communication

24 V d.c. power supply

GJR5251300R0303

07 KT 93 24VDC Extensible central unit with CS31 bus

24 isolated inputs 24 V d.c. and 16 transistor outputs 24 V d.c. / 0.5 A

interface for programming or ASCII or MODBUS
and ARCNET

communication

24 V d.c. power supply

GJR5251300R0363

07 KT 94 24VDC Extensible central unit with CS31 bus

24 isolated inputs 24 V d.c. and 16 transistor outputs 24 V d.c. / 0.5 A

8 channels configurable for inputs or transistor outputs 24 V d.c. / 0.5 A

8 analog inputs and 4 analog outputs

interface for programming or ASCII or MODBUS
communication

24 V d.c. power supply

GJR5252100R0101

07 KT 94 24VDC Extensible central unit with CS31 bus

24 isolated inputs 24 V d.c. and 16 transistor outputs 24 V d.c. / 0.5 A

8 channels configurable for inputs or transistor outputs 24 V d.c. / 0.5 A

8 analog inputs and 4 analog outputs

interface for programming or ASCII or MODBUS
and ARCNET

communication

24 V d.c. power supply

GJR5252100R0161

Presentation / operation

ABB Control - AC 31 Page 1-15

1SBC 260400 R1001-c 01.02

Products Description References

90 Series

Communication couplers

07 KP 90 * RCOM protocol master / slave interface

24 V d.c. power supply.

GJR5251000R0202

07 KP 91 * EIB coupler 1SAY110165R0003

07 MK 92 Two “C” programmable RS232 / RS422 or RS485 interfaces

24 V d.c. power supply

GATS110098R1161

07 KP 93 Two MODBUS
protocol RS232 / RS422 or RS485 interfaces

slave / slave or master

24 V d.c. power supply

GATS110100R0001

07 KP 95 * Coupler for ADVANT AF 100 network GJR5252000R0101

07 KP 96 * PDnet coupler in order to communicate with

24 V d.c. power supply

KOAX

KOAX with redundancy

Optic fiber (plastic) LWL

Optic fiber (plastic) LWL with redundancy

Optic fiber (glass) LWL

Optic fiber (glass) LWL with redundancy

GATS110112R0001

GATS110112R0011

GATS110112R0002

GATS110112R0012

GATS110112R0003

GATS110112R0013

Presentation / operation

Page 1-16 ABB Control - AC 31

1SBC 260400 R1001-c 01.02

Products Description References

Extensible remote units

ICMK 14 F1 24VDC Extensible remote unit

with 8 isolated inputs 24 V d.c. and 6 relay outputs

250 V a.c. / 2 A

24 V d.c. power supply.

1SBP260050R1001

ICMK 14 F1 120/230VAC Extensible remote unit

with 8 isolated inputs 24 V d.c. and 6 relay outputs

250 V a.c. / 2 A

24 V d.c. power supply output to power inputs

120 / 230 V a.c. power supply.

1SBP260051R1001

ICMK 14 N1 24VDC Extensible remote unit

with 8 isolated inputs 24 V d.c. and 6 transistor outputs

24 V d.c. / 0.5 A

24 V d.c. power supply.

1SBP260052R1001

Extensions

XI 16 E1 Binary extension

with 16 isolated inputs 24 V d.c.

1SBP260100R1001

XO 08 R1 Binary extension

with 8 relay outputs 250 V a.c. / 2 A

1SBP260101R1001

XC 08 L1 Binary extension

with 8 channels configurable for inputs or

transistor outputs 24 V d.c. / 0.5 A

1SBP260102R1001

XK 08 F1 Binary extension

with 4 isolated inputs 24 V d.c. and 4 relay outputs

250 V a.c. / 2 A

1SBP260104R1001

XO 16 N1 Binary extension

with 16 transistor outputs 24 V d.c. / 0.5 A

1SBP260105R1001

XO 08 Y1 Binary extension

with 8 transistor outputs 24 V d.c. / 2 A

1SBP260108R1001

XO 08 R2 Binary extension

with 4 NO relay outputs 250 V a.c. / 2 A and 4 NO/NF relay

outputs 250 V a.c. / 3 A

1SPB260109R1001

XM 06 B5 Analog extension

with 4 inputs configurable for current / voltage / Pt 100 / Pt 1000

and 2 outputs configurable for current / voltage

resolution 12 bits

1SBP260103R1001

XE 08 B5 Analog extension

with 8 inputs configurable for current / voltage / Pt 100 / Pt 1000

resolution 12 bits

1SBP260106R1001

XTC 08 Display extension

with 8 channels (4 figures + sign + selected channel)

1SBP260107R1001

30 series plug-in base

ECZ Plug-in base for mounting series 30 remote units FPR 370 0001 R0001

Presentation / operation

ABB Control - AC 31 Page 2-3

1SBC 260400 R1001-c 01.02

In order to familiarize yourself with the AC 31 system this chapter details, point by point, the

necessary operations for starting with a 40 or 50 series central unit. The demonstration is

based on a simple example of OR function with an input (switch), an internal bit (test) and an

output (lamp).

1. Required material

1 central unit : 07 CR 41, 07 CT 41, 07 KR 51 or 07 KT 51

1 power supply depending on the central unit chosen : 24 V d.c., 120 V a.c. or 230 V a.c.

1 programming cable 07 SK 50

1 PC with Windows
3.1 or greater, Windows
NT or Windows
95/98

An installed version of AC31GRAF

The AC31GRAF installation requires 12 Mb of free space on your hard drive.

Follow the installation procedure after having executed "a:setup.exe". Please refer to

the 1SBC006099R1001 software documentation should you encounter a

problem.

The AC31GRAF icon is automatically installed in the ABB AC31GRAF group (see Figure 2-1).

2. Cabling

The cabling example shown in Figure 2-2 is that of a 07 KR 51 central unit 230 V a.c.

The RUN/STOP switch of the central unit should be on STOP.

Please make sure that you have a switch and a lamp so that you can realize the cabling, as

shown opposite, for the demonstration.

3. Programming

3.1. Launching the AC31GRAF software

Double-click the AC31GRAF icon in the ABB AC31GRAF group (see Figure 2-1).

3.2. Project creation

Click on the "New" button in the "Project management" window (Figure 2-3).

The project is defined by its name, programming language and programmed central unit

(see Figure 2-4).

Enter the project name: "DEMO".

Select, by clicking the arrows:

- the language: "LD/FBD" which corresponds to the ladder diagram and function block

language,

- the central unit to be programmed: "series 40" or "series 50".

Click "OK" to validate.

The DEMO:MAIN editor window opens for the main program MAIN of the DEMO project (see

Figure 2-5).

Click on the button in the top right corner to enlarge the window

3.3. Variable declarations

Select the "Variable list" icon in the program editor window (Figure 2-6).

The pre-defined variables in the variable list are those which correspond to the chosen central

unit. The variables of the 40 or 50 series central units are:

- I62.00 to I62.07 for the 8 binary inputs,

- O62.00 to O62.05 for the 6 binary outputs,

- IW62.00 and IW62.01 for the 2 potentiometers,

- M 255.00 to M255.03 for the oscillators

Enter the descriptions for the following variables:

- Select "I62.00" in the list

- Enter: "IN1" without a space and the comment: "Switch"

- Press "OK" to validate

- Create an internal bit "M00.00" by selecting "M" in the variables list available then

enter "00.00"

- Enter: "TEST"

- Press "OK" to validate

- Select "O62.00" in the list

- Enter: "OUT1" and the comment: "Lamp"

- Press "OK" to validate

Press "Exit" to exit. Save by selecting "yes".

3.4. Program editing

3.4.1. Displaying the FBD (function blocks) toolbar

It may be that the LD toolbar is displayed (Figure 2-7).

Should this be the case, click on the "Display FBD toolbar" icon so that the function blocks

toolbar is displayed (result Figure 2-8).

Note that clicking on the "Display LD toolbar" icon will display the LD toolbar again.

3.4.2. Selecting the OR function in the program editor window

Click on the arrow, as indicated in Figure 2-8, in order to obtain the functions list.

Select the "/" function by scrolling through the list with your mouse.

Place the cursor on the blank page (Figure 2-9) and click the mouse to place the "/"

function.

The "/" function block should be completed with 2 parameters:

- an input variable (to the left of the block),

- an internal bit (to the left of the block),

- an output variable (to the right of the block).

A complete description of the function block is available by double-clicking the block and then

clicking on the "Info" followed by the "Note" buttons.

3.4.3. Inserting variables

Select the "Insert variable" icon (Figure 2-10) in the program editor window. Then place

the cursor to the left of the function block, making sure that enough space is left so that the

input variable does not overlap the function block, and click on the mouse.

Select the "I62.00 - IN1 - Switch" variable in the variable list

Validate with "OK". The variable appears with its name.

Comment: If the "Cannot overlap graphic symbols" message appears instead of the

variable then restart the manipulation leaving enough space to the left of the block for the

variable insertion

Use the same procedure to insert the internal bit to the left of the function block and below of

the input variable and select the "M00.00 - TEST" internal bit.

Use the same procedure to insert the output variable to the right of the function block and

select the "O62.00 - OUT1 - Lamp" variable.

3.4.4. Links between the variables and the function block:

Select the "Draw connection line" icon in the program editor window (Figure 2-11) and

draw a line, without releasing the mouse button, between the "IN1" variable and the block.

The link between the "TEST" internal bit and the block is drawn in the same manner.

The link between the "OUT1" variable and the block is drawn in the same manner.

The programming phase is finished once the links are established. You may now save,

compile and send the program to the PLC.

3.5. Saving

Click on the "Save" icon in the program editor window to save your program.

3.6. Compilation

Compiling corresponds to a program verification and translation into a PLC understandable

language.

Click the "Verify program" icon in the program editor window.

Click the "Verify" button, wait for the message "0 error detected" (Figure 2-12) then click on

the "Build" button.

Once the "Project ready for download" message has appeared (Figure 2-13), click on "Exit"

to exit and return to the DEMO:MAIN program editor window.